Calcium-enriched food product

ABSTRACT

The present invention is directed to a calcium-enriched chewable baked food product in which at least one piece of the food product provides the recommended daily DRI of elemental calcium. The calcium-enriched baked food product has a mouth feel, texture and taste substantially similar to a non-calcium-enriched baked food product. The food product also provides Vitamin D 3  in a range of 100-2400 IU and optionally may be enrobed with a flavored coating. The present invention is also directed to a method for producing the calcium-enriched food product.

TECHNICAL FIELD

The present invention is directed to calcium-enriched food products andmore particularly to a chewable calcium dietary supplement.

BACKGROUND OF THE INVENTION

Calcium plays an important role in blood coagulation, nervetransmission, muscle contraction, and heart function. Protection againsthigh blood pressure, colon cancer, and the degenerative bone diseaseknown as osteoporosis have been attributed to calcium. Calcium isrequired in the diet in relatively large quantities. The Food andNutrition Board has established a Dietary Reference Intake (DRI) forcalcium. A daily intake of about 1000 mg of calcium meets most peoplesneeds for general health especially bone health. For older adults andpeople with osteoporosis many clinicians recommend a daily intake ofabout 1200 mg of calcium. Calcium requirements in adolescent childrenand lactating and pregnant women are 1000-1300 mg daily. The publishedDRIs list the recommended DRI by age. The daily adult upper limit “UL”of calcium is 2500 mg. See www.nal.usda.gov. However, the averagecalcium intake may be only about one-third to one-half of therecommended daily dosing. Thus, dietary supplementation of calcium isbeneficial. If dietary sources of calcium do not provide sufficientamounts of calcium to the blood, calcium is depleted from the bones tocompensate for the insufficient amounts. Age related bone loss andfracture rates in patients with osteoporosis may be reduced with highdietary intake of calcium. Calcium absorption efficiency decreases withincreasing intake. Calcium absorption efficiency is greater if calciumis ingested in divided doses.

The ability of different individuals to utilize the calcium in food mayvary considerably. For example, a high protein diet may result in about15% of the dietary calcium being absorbed, whereas a low protein dietmay result in only about 5% of the dietary calcium being absorbed.Moreover, changes in dietary protein in humans alter urinary calciumexcretion. Increased protein consumion results in increased calciumexcretion (Kerstetter, et al., Am J Clin Nutr 1998; 68:859-865). Certaincompounds in food may interfere with calcium absorption. Intestinalfactors that influence the absorption of calcium include pH, thecalcium:phosphorus ratio, the presence of free fatty acids which occurswhen fat absorption is impaired, and the amount of vitamin D. Generally,the more alkaline the contents of the intestines, the less soluble arethe calcium salts. Also, a high calcium:phosphorus ratio favors theformation of tricalcium phosphate rather than the more soluble, betterabsorbed forms. If either calcium or phosphorus is taken in excess,excretion of the other is increased. The optimal ratio is 1:1 when theintake of vitamin D is adequate. Vitamin D promotes the absorption ofcalcium from the intestine. Calcium citrate has been shown to have twoindependent mechanisms for calcium absorption, one is vitamin Ddependent and one vitamin D independent (Favus and Pak; Am J ofTherapeutics 2001; 8:425-431). Many nutritionists believe that thecurrent recommended daily levels of Vitamin D₃ (400 IU) are too low andadvise higher levels.

Although milk has been a major source of calcium for infants and youngchildren, many teenagers and adult Americans are consuming lesseramounts of it. The calcium content of milk and other beverages can beincreased to facilitate meeting the U.S. DRIs for calcium. Calciumenrichment of other foods such as bean curd, yogurt, and cereal grainsis disclosed in U.S. Pat. Nos. 4,676,583, 4,784,871, and 4,765,996,respectively.

Calcium compounds have been utilized in baked goods such as crackers, ascomponents of leavening agents, as pH adjusters, in yeast foods, and forits nutritive value. However, calcium-fortified baked goods typicallyhave a dry mouth feel, a dry and hard texture and a very chalky taste ascompared to a noncalcium-fortified baked product.

U.S. Pat. No. 5,514,387 is directed to calcium-enriched baked goods andteaches the tenderization of calcium-enriched crackers and other bakedgoods in which the dough includes an emulsifying amount of at least onepoly-oxyethylene sorbitan fatty acid ester and at least one stearoyllactylate. U.S. Pat. No. 4,196,226 discloses a leavening acid comprisingalkali metal aluminum phosphate granules having a calcium rich outersurface for improving flow and dusting properties. U.S. Pat. Nos.6,495,191 and 6,126,982 disclose wheat flour for mineral-enhanced bakeryproducts having at least an additional 2-20% by weight of dietaryminerals.

It would be desirable to have a chewable calcium-enriched baked foodproduct that meets the requirements for a Dietary Supplement that hasacceptable mouth feel, appearance, taste, aroma, and texture in which atleast one piece of the food product provides the recommended daily DRIof calcium and a Vitamin D₃ range of 100-2400 IU.

BRIEF SUMMARY OF THE INVENTION

The present invention is directed to a calcium-enriched chewable bakedfood product in which at least one piece of the food product providesthe recommended daily DRI of calcium. The calcium-enriched baked foodproduct has a mouth feel, texture and taste substantially similar to anon-calcium-enriched baked food product. At least one piece of the foodproduct provide calcium in the range of 100-1500 mg, more preferably onepiece of the food product provides calcium in the range of 100-650 mgand most preferably, the amount of calcium in each piece is 500 mg. Eachpiece of the food product also provides Vitamin D₃ in a range of100-2400 IU.

Optionally, the baked food product can be enrobed with a flavoredcoating.

The calcium is selected from a group of calcium sources consisting ofcalcium citrate, calcium gluconate, calcium lactate, calcium carbonate,calcium phosphate and calcium citrate malate. In the food product, lessthan 100% of the calcium citrate has a particle size less than 100 μm;less than 99% of the calcium citrate has a particle size less than 40μm; and less than 90% of the calcium citrate has a particle size lessthan 20 μm. The preferred median particle size is 2-6 μm.

The baked food product is selected from a group consisting of a flavoredcake, a brownie, a strudel and other cake-like products, can have abakery type interior and optionally is enrobed with a flavored coating.

The baked food product has a flavor selected from a group consisting ofchocolate, chocolate mint, lemon, caramel, cappuccino, cinnamon, maple,butter, fruit flavors, vanilla, peanut butter, and carrot flavored cake.

The coating has a flavor selected from a group consisting of chocolate,chocolate mint, lemon, caramel cappuccino, cinnamon, maple, butter,fruit flavors, vanilla, yogurt and peanut butter.

Each piece of the unenrobed food product has a weight preferably in therange of 3.5 to 24 grams and each piece of the food product canoptionally be completely enrobed with 0.5-8 grams of coating.

The present invention is also directed to a method for producing acalcium-enriched baked food product, the food product being chewable andproviding the recommended daily DRI of calcium. The method includes thesteps of: a) mixing selected wet and dry ingredients in a mixer to forma mixed dough/batter; b) feeding the mixed dough/batter through anextruder; c) cutting the extruded dough/batter into individual pieceseither before or after baking; d) baking the extruded dough/batter; e)enrobing the individual pieces; and f) packing the pieces into anynumber of packaging configurations such as trays. The method therebyprovides a chewable calcium-enriched food product in which at least onepiece of the food product provides the recommended daily DRI of calciumand the food product has a mouth feel, texture and taste substantiallysimilar to a non-calcium-enriched baked food product.

The foregoing has outlined rather broadly the features and technicaladvantages of the present invention in order that the detaileddescription of the invention that follows may be better understood.Additional features and advantages of the invention will be describedhereinafter which form the subject of the claims of the invention. Itshould be appreciated by those skilled in the art that the conceptionand specific embodiment disclosed may be readily utilized as a basis formodifying or designing other structures for carrying out the samepurposes of the present invention. It should also be realized by thoseskilled in the art that such equivalent constructions do not depart fromthe spirit and scope of the invention as set forth in the appendedclaims. The novel features which are believed to be characteristic ofthe invention, both as to its organization and method of operation,together with further objects and advantages will be better understoodfrom the following description when considered in connection with theaccompanying figures. It is to be expressly understood, however, thateach of the figures is provided for the purpose of illustration anddescription only and is not intended as a definition of the limits ofthe present invention.

BRIEF DESCRIPTION OF THE DRAWINGS

For a more complete understanding of the present invention, reference isnow made to the following descriptions taken in conjunction with theaccompanying drawings, in which:

FIG. 1 is a perspective view of inventive food product;

FIG. 2 is a perspective view of the food product of FIG. 1 showing theinterior of the food product;

FIG. 3 is a flow chart of the process steps for producing the inventivefood product;

FIG. 4 is a perspective view of packaging for a single serving of thefood product of FIG. 1; and

FIG. 5 is a perspective view of an embodiment of a multi-pack formedfrom the packaging of FIG. 4.

DETAILED DESCRIPTION OF THE INVENTION

As used herein, the use of the word “a” or “an” when used in conjunctionwith the term “comprising” in the claims and/or the specification maymean “one,” but it is also consistent with the meaning of “one or more,”“at least one,” and “one or more than one.”

Water activity is a measurement of the energy status of the water in asystem; represented by a quotient between water's partial pressure inthe food and pure water's partial pressure. It indicates how tightlywater is bound, structurally or chemically, within a substance. This ismeasured by equilibrating the liquid phase (in the sample) with thevapor phase (in the headspace) and measuring the relative humidity ofthat space. A major application of water activity concerns the controlof microbial growth. The control of microbial growth is a significantcomponent of food safety. Most pathogenic bacterial growth in foodproducts can be stopped by water activity (aw)≦0.85. To stop yeast andmold growth it is necessary to have aw≦0.75. Moisture is a quantitativeanalysis to determine the total amount of water present in a sample.

Sources of calcium that is micronized have particles of a very smallsize, for example less than 100% of the micronized calcium particles areless than 100 μm in size.

Mouthfeel is the mingled experience deriving from the sensations of themucus membrane in the mouth during and/or after ingestion of a food orbeverage. It relates to density, moisture, viscosity, surface tensionand other physical properties of the food or beverage being sampled.

A daily intake of about 1000 mg of calcium is the recommended DietaryReference Intake (DRI) for calcium that meets most peoples needs (19-50yrs) for general health especially bone health. For older adults (over50 yrs) and people with osteoporosis the recommend DRI is about 1200 upto 1500 mg of calcium depending upon bone health. The required DRI ofcalcium in adolescent children (9-18 yrs) and lactating and pregnantwomen is about 1300 mg daily. The required DRI of calcium for infants7-12 months is 270 gm daily, for young children 1-3 yrs is 500 gm daily,and children 4-8 is 800 mg daily.

As known to one skilled in the art of food technology, creamy isgenerally specified as having a combination of moderate to highviscosity, non-Newtonian flow, the presence of some fat and otherfactors. Foods that are creamy are very smooth and have to be free fromgritty, lumpy, grainy or abrasive properties.

Non-calcium enriched baked food products have a soft texture, anacceptable moist mouthfeel, do not have an off-taste, and are free ofgritty and grainy properties. Increasing the calcium content of bakedfood products typically adversely affects the mouthfeel, taste andtexture of the baked food product, resulting in a food product that hasa dry mouthfeel, a caulky taste and a hard texture.

In the present invention, it has been found that the calcium content ofthe chewable food product can be increased by the use of a micronizedcalcium source. The use of micronized calcium, preferably calciumcitrate, results in a baked food product that has an acceptable moistmouthfeel, a soft texture and a taste that is comparable to anon-calcium-enriched baked food product.

Baked food product 10 of the present invention can include for example aflavored cake, a brownie, or a strudel or other cake-like product (FIG.1). The baked food product preferably has a bakery-type interior and anoptional exterior coating. Preferably, the mouthfeel is creamy andsmooth. In a preferred embodiment, the chewable calcium citrate foodproduct 10 is a flavored cake 12 optionally enrobed in a flavoredcoating 14 (FIG. 2). The product also contains Vitamin D₃. Any flavoringcan be used for the cake and coating. Some examples of flavorings can beselected from flavors such as chocolate, chocolate mint, lemon, caramel,cappuccino, cinnamon, maple, butter, fruit flavors, vanilla, peanutbutter, and a carrot flavored cake with an appropriate coating.

Preferably, the calcium source is “calcium citrate tetrahydrate, USPUltra Fine” from suppliers such as Jost Chemical Co, Inc. St. Louis,Mo.; Jungbunzlauer Ladenburg GmbH, Ladenburg; or Boehringer IngelheimGmbH, Ingelheim Germany. In a preferred embodiment, less than 100% ofthe calcium source has a particle size less than 100 μm. In a morepreferred embodiment, less than 99% of the calcium source has a particlesize below 40 μm. In a most preferred embodiment, less than 90% of thecalcium source has a particle size below 20 μm, with a median particlesize between 2-6 μm. Other sources of calcium such as calcium gluconate,calcium lactate, calcium carbonate, and calcium citrate malate can beused as well as other known calcium sources. Preferably, the calciumsources have a lead level that is less than 0.10μ per one gram ofcalcium source and more preferably less than 0.020μ per one gram ofcalcium source.

Each unenrobed chewable piece can be formed into various sizes andweights. Examples of different sizes and weights are shown in the tablebelow with the respective amount of calcium, Vitamin D₃, and caloriesfor each.

Weight Calcium Vitamin D₃ Calories Size 3.5 grams +/− 100-500 mg, 100-600 IU 14-16 ⅜″ length, 5% preferably ⅞″ width, 250 mg ⅔″ height  9 grams +/− 100-650 mg, 200-1200 IU 35-40 ⅞″ length, 3% preferably ⅞″width, 500 mg ⅔″ height  18 grams +/− 500-1200 mg, 400-2400 IU 70-80 1¾″length, 3% preferably ⅞″ width, 1000 mg ⅔″ height  24 grams +/− 500-1500mg, 400-2400 IU  90-110 2⅓″ length, 3% preferably ⅞″ width, 1300 mg ⅔″height

The chewable food product has a moisture content of 13-15%, preferably14%, and a water activity of less than 0.8, preferably less than 0.75.The enrobed food product can have the following amount of coating: 3.5gm piece can have about 0.5-2 gm of coating, preferably 1 gm; 9 gm piececan have about 1.5-4 gm of coating, preferably 2 gm; 18 gm piece canhave about 3-6 gm of coating, preferably 4 gm; and the 24 gm piece canhave about 4-8 gm of coating, preferably 5.5 gm.

At least one piece of the chewable food product can provide therecommended daily DRI of calcium depending upon the age of the personand the size of the food product. The chewable food product also has notrans fat, a low lead level and is low in carbohydrates. The amount ofcalcium in each piece will depend upon the size of the chewable piece orthe size can be kept constant and the amount of calcium varied. Forexample, a piece weighing 3.5-12 grams can provide calcium in the rangeof 100-650 mg. Two 9 gram pieces having 500 mg calcium each, can providea daily DRI of 1000 mg of calcium. Therefore, the number of pieces thatwill meet the recommended daily DRI for calcium will depend upon thesize and weight of the chewable piece. However, calcium absorptionefficiency is greater if calcium is ingested in divided doses.

The ingredients in the baked food product can include for example,sugar, calcium citrate, enriched bleached flour (niacin, reduced iron,thiamine mononitrate, riboflavin, folic acid), egg, oils such aspartially hydrogenated palm kernel and palm oils and soybean oil, cornsyrup, whey, natural and artificial flavors, cocoa, xanthan gum,glycerol, soy lecithin, artificial colors, sodium benzoate, phosphoricacid, potassium sorbate, salt, and Vitamin D₃. The baked food productcan optionally be enrobed with a flavored coating.

The chewable food product 10 of the present invention has an extendedshelf-life, preferably a shelf-life of 18-24 months. This is achieved byreducing both the oxygen level and the water activity of the product.Preferably, the oxygen level is as low as possible without producingchanges to the flavor or appearance of the product. The deterioration offoods by microorganisms can take place rapidly during storage. Moisturecontent is an important factor in controlling the rate of deteriorationin food products. It is the availability of water for microbial activitythat determines the shelf-life of a food and this is measured by thewater activity of a food. Thus, it is desirable that the water activityof the chewable food product be less than 0.8 and preferably less than0.75. Therefore, a low oxygen level and a water activity level less than0.8 provides for a fresh tasting and stable product that will remain forthe product's shelf-life of 18-24 months.

As illustrated in the flow chart of FIG. 3, the chewable food product ofthe present invention is formed by mixing the dry ingredients and wetingredients in a mixer 16. In a preferred embodiment, a vertical mixeris used. Mixing is timed to ensure content uniformity of allingredients, especially the active ingredients. The mixed dough/batteris fed through an extruder 18, such as a twin screw extruder. In apreferred embodiment, a ve-mag extruder is used because of the need tominimize the entrapped air in the food product. This is becauseentrapped air will cause weight variation of the food product and inorder for food products to be suitable as a dietary supplement, certainweight tolerances need to be met. In a most preferred embodiment, theve-mag extruder has a vacuum chamber to keep the extruder head filled ata constant level and to provide positive pressure to the twin extruder.

The extruded dough/batter is cut 20 into pieces at pre-baking orpost-baking, preferably pre-baking. The food product is preferably cutwith a double reciprocating guillotine. If the food product is cutpre-bake, then after cutting the product is baked. If the food productis cut post-bake, the product is baked and then cut. One can optimizethe dough consistency for ease of extrusion. Changing the timing of theguillotine cutting and the conveyor speed will result in a food productof varying concentration of the calcium and Vitamin D₃. Alternatively,the amount of calcium and Vitamin D₃ in the dough mixture can be variedand the food product size kept constant. This allows for a customizationof the food product to meet the varying recommended daily DRIs forcalcium.

The extruded product is baked 22 at a temperature range of 225-275° F.,for thirteen to fifteen minutes, preferably thirteen minutes, withheating sources known to one skilled in the art of baking. In apreferred embodiment, the heat source is a combination of 10-20%convection and 80-90% radiant heat, with a preferred combination of 10%convection and 90% radiant. The time and temperature of baking areadjusted in accordance with conventional techniques, to provide ashelf-stable moisture content.

After baking, the product is cooled in a cooling tunnel 24 to theambient temperature of the process room. The immediate cooling minimizesdegradation of the Vitamin D₃. Thereafter, each piece can be enrobed 26with a coating using a standard confectionary enrober known to oneskilled in the art of food production. In a preferred embodiment, eachpiece is completely enrobed with a coating. For example the 3.5 gm piececan have about 0.5-2 gm of coating, preferably 1 gm; the 9 gm piece canhave about 1.5-4 gm of coating, preferably 2 gm; the 18 gm piece canhave about 3-6 gm of coating, preferably 4 gm; and the 24 gm piece canhave about 4-8 gm of coating, preferably 5.5 gm. The invention providesa delivery system for vitamins such as Vitamin A, the Vitamin B group,Vitamin C, D and K; minerals such as magnesium, manganese, zinc,magnesium, iron, and phosphorus; and functional ingredients such asantioxidant and other related compounds; flavor masking agents; andmicroencapsulated active compounds. This is not an exclusive list ofcontemplated vitamins, minerals and functional ingredients. The coatingtotally encapsulates each piece substantially protecting the Vitamin D₃and other labile vitamins and ingredients from light and certain oxygensources that can cause degradation. Once the product is enrobed ittravels again through a cooling tunnel 28 in order to set the coating.

One skilled in the art of food technology knows that the contemplatedshipping conditions of an enrobed food product will impact the choice ofthe enrobing material. Generally, if a low melt point enrobing materialin the range of 102-110° F. is used, the enrobed food product willrequire refrigerated or controlled cool shipping conditions.Alternatively, if a high melt point enrobing material in the range of110-130° F. is used, the enrobed food material can be shipped undernon-refrigerated conditions and will withstand adverse environmentalconditions in most places. In a preferred embodiment, a high melt pointenrobing material having a melt point of 117° F. can be used in order toprevent the coating from melting during most shipping conditions. Theenrobing material can be obtained from sources such as GuittardChocolate Company, Burlingame, Calif.; AMD, Decatur, Ill. or ClasenQuality Coating, Inc., Madison, Wis.

After the coating has set, the product may be transferred to a packingarea via conveyors or by moving manually. A standard horizontal form,fill and seal machine is used. In a preferred embodiment, a high barrierlaminated film structure is thermo-formed into “blister” cavity trays 30and a robotic pick and place system 32 fills the trays with the chewablefood product. The filled trays pass into a sealing station 34 where theatmosphere is modified to remove oxygen from the headspace of the traycavity and replace it with inert gas. In a preferred embodiment, theinert gas is composed of 0-20% carbon dioxide and 80-100% nitrogen. Thetrays are hermetically sealed with a foil laminate film having certainbarrier properties. In a preferred embodiment, the foil laminate filmhas an Oxygen Transmission Rate of 0.019-0.026 cc/(100 in day) and aWater Vapor Transmission Rate of 0.068, +/3% gm/(100 in² day). Theproduct is thereafter loaded into a variety of retail packagingconfigurations 36.

In one example of the packaging 38, the each piece of the food product10 is placed in an individual tray 40 having a foil laminate film 42(FIG. 4). The trays 40 can be configured in a pack 44 consisting of tworows of three trays each in which the edges of the trays 40 haveperforations 46 for easy separation (FIG. 5).

It is understood that all processing steps can be performed manuallywith out the need for mixers, extruders, cutters, cooling tunnels orautomated packaging devices.

The present invention is further illustrated in the following examples,where all parts, ratios and percentages are by weight, and alltemperatures are in ° F., unless otherwise stated:

EXAMPLE 1

One example is a 9 gram sized brownie that is dipped in a chocolateflavored coating. The ingredients and their relative amounts may be usedto produce a calcium enriched brownie that provides about 500 mg calciumand about 200 IU of Vitamin D₃

Brownie Ingredients w/w % Powder sugar 27-30% Cake flour 11-14% Wholeeggs dried 1-4% Corn starch  .3-1.3% Nonfat dry milk  .9-2.5% Cocoapowder  .5-2.5% Xanthan gum .25-.4%  Salt  .5-1.5% Calcium Citrate26.6-28.6% Potassium Sorbate .075-.15%  Water 6-9% Corn syrup 2.5-4%  Glycerol  .5-1.5% Soybean oil 6-9% Vanilla extract .15-.7%  Chocolateextract 1.5-3.5% Brown color .009-.015% Coffee emulsion .002-.01% Vitamin D₃ (100,000 IU/G) .029-.035%

The dry and wet ingredients for the brownie are mixed in a verticalmixer and the mixed batter is fed through a ve-mag extruder. Theextruded product is cut and then baked with a combination of 10%convection and 90% radiant heat for thirteen minutes and at 225-275° F.or after baking the product is cut. Regardless of when the cutting takesplace, the food product is cut into pieces with a double reciprocatingguillotine. Thereafter, the product is cooled to the ambient temperatureof the process room.

Each piece is enrobed with about 2 grams of a chocolate flavored coatingusing a standard chocolate enrober set up. Once the pieces are enrobedthey travel through a cooling tunnel in order to set the coating. Afterthe coating has set, the pieces are transferred to a packing area forpackaging into “blister” cavity trays. The filled trays are hermeticallysealed with a foil laminate film. The filled trays are thereafter loadedinto a variety of retail packaging configurations.

EXAMPLE 2

Another example is a 9 gram piece of lemon flavored cake dipped in alemon flavored coating. The ingredients and their relative amounts maybe used to produce a calcium enriched cake that provides about 500 mgcalcium and about 200 IU of Vitamin D₃

Cake Ingredients w/w % Powder sugar 29-32% Cake flour 13-16% Whole eggsdried 1.5-3.0% Corn starch .2-1%  Nonfat dry milk  .5-2.5% Xanthan gum .2-.65% Salt  .5-1.5% Calcium Citrate 26.6-28.6% Potassium Sorbate.06-1.1% Corn syrup 2-4% Glycerol .8-2%  Soybean oil 6-9% Water 6-9%Vanilla extract  .2-1.1% Yellow color .003-.009% Lemon extract,concentrated  .3-1.2% Vitamin D₃ (100,000 IU/G) .029-.035%

The dry and wet ingredients for the cake are mixed in a vertical mixerand the mixed batter is fed through a ve-mag extruder. The extrudedproduct is cut and then baked with a combination of 10% convection and90% radiant heat for thirteen minutes and at 225-275° F. or after bakingthe product is cut. Regardless of when the cutting takes place, the foodproduct is cut into pieces with a double reciprocating guillotine.Thereafter, the product is cooled to the ambient temperature of theprocess room.

Each piece is enrobed with about 2 grams of a lemon flavored coatingusing a standard enrober set up. Once the pieces are enrobed they travelthrough a cooling tunnel in order to set the coating. After the coatinghas set, the pieces are transferred to a packing area for packaging into“blister” cavity trays. The filled trays are hermetically sealed with afoil laminate film. The filled trays are thereafter loaded into avariety of retail packaging configurations.

EXAMPLE 3

Another example is a 9 gram piece of caramel flavored cake dipped in acaramel flavored coating. The ingredients and their relative amounts maybe used to produce a calcium enriched cake that provides about 500 mgcalcium and about 200 IU of Vitamin D₃.

Cake Ingredients w/w % Powder sugar 28-32% Cake flour 13-16% Whole eggsdried 1.5-3%   Corn starch  .3-1.1% Nonfat dry milk  .8-2.2% Xanthan gum.1-.5% Salt   .5-1.5% Calcium Citrate 26.6-28.6% Potassium Sorbate.08-.13% Corn syrup 1.9-3.5% Glycerol .75-1.5% Soybean oil 6-9% Water7-9% Vanilla extract  .1-1.3% Yellow color .008-.012% Caramel flavor1-3% Caramel color .01-.09% Vitamin D₃ (100,000 IU/G) .029-.035%

The dry and wet ingredients for the cake are mixed in a vertical mixerand the mixed batter is fed through a ve-mag extruder. The extrudedproduct is cut and then baked with a combination of 10% convection and90% radiant heat for thirteen minutes and at 225-275° F. or after bakingthe product is cut. Regardless of when the cutting takes place, the foodproduct is cut into pieces with a double reciprocating guillotine.Thereafter, the product is cooled to the ambient temperature of theprocess room.

Each piece is enrobed with about 2 grams of a caramel flavored coatingusing a standard enrober set up. Once the pieces are enrobed they travelthrough a cooling tunnel in order to set the coating. After the coatinghas set, the pieces are transferred to a packing area for packaging into“blister” cavity trays. The filled trays are hermetically sealed with afoil laminate film. The filled trays are thereafter loaded into avariety of retail packaging configurations.

EXAMPLE 4

Another example is a 9 gram piece of chocolate mint flavored cake dippedin a chocolate mint flavored coating. The ingredients and their relativeamounts may be used to produce a calcium enriched cake that providesabout 500 mg calcium and about 200 IU of Vitamin D₃.

Cake Ingredients w/w % Powder sugar 26-29% Cake flour 11-14% Whole eggsdried 1.5-3%   Corn starch  .3-1.1% Nonfat dry milk  .9-2.5% Cocoapowder  .9-2.5% Xanthan gum .1-.6% Salt  .6-1.3% Calcium Citrate26.6-28.6% Potassium Sorbate .09-.13% Water 5-8% Corn syrup 2.5-3.9%Glycerol .75-2%   Soybean oil 6-9% Vanilla extract  .1-1.5% Mint flavor2-4% Vitamin D₃ (100,000 IU/G) .029-.035%

The dry and wet ingredients for the cake are mixed in a vertical mixerand the mixed batter is fed through a ve-mag extruder. The extrudedproduct is cut and then baked with a combination of 10% convection and90% radiant heat for thirteen minutes and at 225-275° F. or after bakingthe product is cut. Regardless of when the cutting takes place, the foodproduct is cut into pieces with a double reciprocating guillotine.Thereafter, the product is cooled to the ambient temperature of theprocess room.

Each piece is enrobed with about 2 grams of a chocolate mint flavoredcoating using a standard enrober set up. Once the pieces are enrobedthey travel through a cooling tunnel in order to set the coating. Afterthe coating has set, the pieces are transferred to a packing area forpackaging into “blister” cavity trays. The filled trays are hermeticallysealed with a foil laminate film. The filled trays are thereafter loadedinto a variety of retail packaging configurations.

Although the present invention and its advantages have been described indetail, it should be understood that various changes, substitutions andalterations can be made herein without departing from the spirit andscope of the invention as defined by the appended claims. Moreover, thescope of the present application is not intended to be limited to theparticular embodiments of the process, machine, manufacture, compositionof matter, means, methods and steps described in the specification. Asone of ordinary skill in the art will readily appreciate from thedisclosure of the present invention, processes, machines, manufacture,compositions of matter, means, methods, or steps, presently existing orlater to be developed that perform substantially the same function orachieve substantially the same result as the corresponding embodimentsdescribed herein may be utilized according to the present invention.Accordingly, the appended claims are intended to include within theirscope such processes, machines, manufacture, compositions of matter,means, methods, or steps.

1.-18. (canceled)
 19. A method for producing a calcium-enriched bakedfood product, the food product being chewable and providing therecommended daily DRI of calcium, the method comprising the steps of: a)mixing selected wet and dry ingredients in a mixer to form a mixeddough/batter; b) feeding the mixed dough/batter through an extruder; c)cutting the extruded dough/batter into individual pieces either beforeor after baking; d) packing the baked pieces into packing materialthereby providing a chewable calcium-enriched food product in which atleast one piece of the food product provides enough calcium to achievethe recommended daily DRI of calcium and the food product has a mouthfeel, texture and taste substantially similar to a non-calcium-enrichedbaked food product; and wherein the calcium enriched food productcomprises between 2.30% and 18.57% elemental calcium.
 20. The method ofclaim 19, further including the step of completely enrobing theindividual pieces with an exterior coating prior to packing the piecesinto the trays.
 21. The method of claim 19, further including the stepof completing the baking process of the extruded dough/batter after itis cut.
 22. The method of claim 19, wherein the trays are blister cavitytrays that are hermetically sealed after filling.
 23. The method ofclaim 19, wherein the at least one piece of the food product providecalcium the range of 100-1500 mg.
 24. The method of claim 23, whereinone piece of the food product provides calcium in the range of 100-650mg.
 25. The method of claim 24, wherein the calcium is about 500 mg. 26.The method of claim 19, wherein at least one piece of the food productalso provides Vitamin D₃ in a range of 100-2400 IU.
 27. The method ofclaim 26, wherein each piece of the food product provides Vitamin D₃ ina range of 200-1200 IU.
 28. The method of claim 19, wherein the calciumis selected from a group of calcium sources consisting of calciumcitrate, calcium gluconate, calcium lactate, calcium carbonate, calciumphosphate, and calcium citrate malate.
 29. The method of claim 28,wherein less than 100% of the calcium source has a particle size lessthan 100 μm.
 30. The method of claim 29, wherein less than 99% of thecalcium source has a particle size less than 40 μm.
 31. The method ofclaim 30, wherein less than 90% of the calcium source has a particlesize less than 20 μm.
 32. The method of claim 19, wherein the foodproduct is selected from a group consisting of a flavored cake, abrownie, and a strudel.
 33. The method of claim 32, wherein the foodproduct has a bakery interior.
 34. The method of claim 32, wherein thefood product is enrobed with a flavored coating.
 35. The method of claim32, wherein the food product has a flavor selected from a groupconsisting of chocolate, chocolate mint, lemon, caramel, cappuccino,cinnamon, maple, butter, fruit flavors, vanilla, peanut butter, andcarrot flavored cake.
 36. The method of claim 34, wherein the coatinghas a flavor selected from a group consisting of chocolate, chocolatemint, lemon, caramel, cappuccino, cinnamon, maple, butter, fruitflavors, vanilla, and peanut butter.
 37. The method of claim 19, whereineach piece of unenrobed the food product has a weight in the range of3.5 to 24 grams.
 38. The method of claim 19, wherein each piece of thefood product is completely enrobed with 0.5-8 grams of coating.
 39. Themethod of claim 19, wherein the food product has an extended shelf-lifeof 1-26 months.